I just had this fear that I'll send allll this money, put it back together, and something I haven't fixed will rear up and destroy all the new parts. Like if I had opened it up and there was something clearly getting destroyed I'd feel better, cause I'd know that's where everything came from. But this...

John

I sympathise with this completely

Everytime I do a patch fix on my engine because finance dictates it, instead of replacing everything I see that could maybe do with replacing, I live in this paranoid fear that the universe is gonna get me Sad but true

In the end it´s probably just a question of going with general consensus and relying on your own judgement and that of the people here and go with it, there´s some real experience based expertise floating around these parts of the interweb

Ok so I had a look at the gears. I took lots of photos so if any of you feel so inclined and make a judgement that would be fantastic. I thought I would just upload them all to a photobucket album so you could browse at your leisure:

C1 (largest of the CS), is scored where it meets with C4 but the holes don't seem to be that worn. Small chip in one of the teeth.

C4 has a little wear in the bit where the fork sits and around the edges of the larger dogs but doesn't look too bad. Smaller dogs on other side are worn at the edges if they came from the factory at a cut stright (make 90 degrees)? I'm not sure though, I can't find a photo of a stock gear to really see if they are meant to be perfectly sharp edges...
Some light scorning on the faces of the dogs on both sides of C4

C5 teeth seem to be at a greater angle on the side it meets C2 than on the side it butts against C3. Again, I'm not sure if it is meant to be like this? There does seem to be a fair bit of scoring in the part where the fork sits, certainly more than is seen in C4.

Now C2 has very worn holes from the dogs of C5, as can be obviously seen in the photos. They aren't in the same shape as they meant to be and the edges are missing metal.

Mainshaft

M2 is one of the few gears that has clearly pitted teeth, one is very bad with three more that have a hole or two.

M5 teeth seem ok, but the holes where the dogs engage seem to worn a little (like was seen in C2).

Rest of mainshaft seems ok

Shift Forks

Now this might be where the metal is coming from? All three of the shift forks are shiny and worn where they contact the different gears (as can bee seen in the photos). Is this normal? If so, I have no idea where the metal is coming from!

Thanks,

John

Hi John

Here you find Fotos from a 87 XR Gears , maybe it helps .
Pic is very large , use zoom to see the details .